Robust Through-Silicon-Via Structure

ABSTRACT

Methods and apparatus entailing an interconnect structure comprising interconnect features disposed in dielectric material over a substrate. Each interconnect feature comprises an interconnect member and a via extending between the interconnect member and a conductive member formed within the dielectric material. A through-silicon-via (TSV) structure is formed laterally offset from the interconnect structure by forming a first portion of the TSV structure with a first conductive material and forming a second portion of the TSV structure with a second conductive material. Forming the second portion of the TSV structure occurs substantially simultaneously with forming one of the interconnect features.

PRIORITY CLAIM AND CROSS-REFERENCE

This application is a divisional and claims the benefit of U.S. patentapplication Ser. No. 14/158,577, filed on Jan. 17, 2014, entitled“Robust Through-Silicon-Via Structure,” which is incorporated herein byreference.

BACKGROUND

Two semiconductor wafers, dies, and/or other substrates may be assembledutilizing through-silicon-via (TSV) structures that extend through thethickness of the substrate. However, as such devices continue todecrease in size, lower metallization layers of the includedinterconnect structures are evolving from single-damascene todual-damascene structures. This evolution, however, renders the TSVstructure susceptible to popping up, due at least in part to theelimination of the metal pad that previously covered the TSV structure.Moreover, the additional manufacturing steps that would be required toreintroduce the metal pad covering the TSV structure would excessivelydrive up complexity and device cost while potentially decreasing productyield.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is best understood from the following detaileddescription when read with the accompanying figures. It is emphasizedthat, in accordance with the standard practice in the industry, variousfeatures are not drawn to scale. In fact, the dimensions of the variousfeatures may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 is a sectional view of at least a portion of apparatus accordingto one or more aspects of the present disclosure.

FIG. 2 is a sectional view of the apparatus shown in FIG. 1 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 3 is a sectional view of the apparatus shown in FIG. 2 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 4 is a sectional view of the apparatus shown in FIG. 3 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 5 is a sectional view of the apparatus shown in FIG. 4 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 6 is a sectional view of the apparatus shown in FIG. 5 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 7 is a sectional view of at least a portion of apparatus accordingto one or more aspects of the present disclosure.

FIG. 8 is a sectional view of the apparatus shown in FIG. 7 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 9 is a sectional view of the apparatus shown in FIG. 8 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 10 is a sectional view of the apparatus shown in FIG. 9 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 11 is a sectional view of the apparatus shown in FIG. 10 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 12 is a sectional view of the apparatus shown in FIG. 11 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 13 is a sectional view of the apparatus shown in FIG. 12 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 14 is a sectional view of the apparatus shown in FIG. 13 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 15 is a sectional view of the apparatus shown in FIG. 14 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 16 is a sectional view of the apparatus shown in FIG. 15 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 17 is a sectional view of the apparatus shown in FIG. 16 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 18 is a sectional view of at least a portion of apparatus accordingto one or more aspects of the present disclosure.

FIG. 19 is a sectional view of the apparatus shown in FIG. 18 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 20 is a sectional view of the apparatus shown in FIG. 19 in asubsequent stage of manufacture according to one or more aspects of thepresent disclosure.

FIG. 21 is a sectional view of at least a portion of apparatus accordingto one or more aspects of the present disclosure.

DETAILED DESCRIPTION

It is to be understood that the following disclosure provides manydifferent embodiments, or examples, for implementing different featuresof various embodiments. Specific examples of components and arrangementsare described below to simplify the present disclosure. These are, ofcourse, merely examples and are not intended to be limiting. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.Moreover, the formation of a first feature over or on a second featurein the description that follows may include embodiments in which thefirst and second features are formed in direct contact, and may alsoinclude embodiments in which additional features may be formedinterposing the first and second features, such that the first andsecond features may not be in direct contact.

FIG. 1 is schematic view of at least a portion of an apparatus 100 in anintermediate stage of manufacture according to one or more aspects ofthe present disclosure. The apparatus 100 is fabricated from and/or on asubstrate 105, which may comprise bulk silicon, strained silicon,silicon germanium, and/or other materials. The substrate 105 may also beor comprise a silicon-on-insulator (SOI) substrate, such as asilicon-on-sapphire substrate, a silicon germanium-on-insulatorsubstrate, and/or another substrate comprising an epitaxialsemiconductor layer on an insulator layer. However, the substrate 105may comprise additional or alternative materials within the scope of thepresent disclosure. The substrate 105 may have a <100>, <110>, <111>, orother surface orientation. The substrate 105 may also comprise at leastportions of one or more active and/or passive devices (not shown), suchas transistors, capacitors, resistors, inductors, and/or other devicesthat may be utilized to generate the desired structural and functionalrequirements of the design. Such devices may be formed by any suitablemethods, whether within and/or on the surface of the substrate 105.

The apparatus 100 also comprises an interlayer dielectric (ILD) layer110 overlying at least portions of the substrate 105. The ILD layer 110may comprise one or more layers of silicon oxide, BLACK DIAMOND (aproduct of Applied Materials of Santa Clara, Calif.), and/or othermaterials, which may be formed by chemical-vapor deposition (CVD),sputtering, spin-on coating, and/or other processes. The thickness ofthe ILD layer 110 may range between about 1500 angstroms and about 8000angstroms, although other thicknesses are also within the scope of thepresent disclosure.

The apparatus 100 also comprises one or more conductive members 115extending through the thickness of the ILD layer 110. The conductivemembers 115 may be formed in openings that are defined in the ILD layer110 by applying and developing a suitable photoresist (not shown), andthen etching the ILD layer 115 to generate the openings. The openingsfor the conductive members 115 may be partially or substantially linedwith a barrier layer (not shown) prior to formation of the conductivemembers 115. The barrier layer may comprise one or more layers ofconductive and/or dielectric materials, such as titanium, titaniumnitride, tantalum nitride, titanium, silicon nitride, silicon oxide,and/or other materials, which may be formed utilizing CVD,plasma-enhanced CVD (PECVD), metal organic CVD (MOCVD), sputtering,and/or other processes.

The conductive material forming the conductive members 115 may comprisecopper, aluminum, doped polysilicon, combinations thereof, and/or othermaterials, and may be formed by various CVD processes, perhaps includingdepositing a seed layer and then electroplating copper onto the seedlayer. Grinding, chemical mechanical planarizing (CMP), and/or otherprocesses may then be utilized to remove a portion of the conductivematerial to define the conductive members 115 flush with the uppersurface 112 of the ILD layer 110.

The conductive members 115 may each extend through the ILD layer 110 tothe substrate 105 and/or to a corresponding feature 120 formed on and/orin the substrate 105. For example, the feature 120 may comprise alanding pad, a bond pad, a trace, a contact of one or more active and/orpassive devices, and/or other conductive elements.

FIG. 2 is a cross-sectional view of a portion of the apparatus 100 shownin FIG. 1 in a subsequent stage of manufacture, in which a portion of aninterconnect structure 125 has been formed in a first inter-metaldielectric (IMD) layer 130 and a second IMD layer 135. The interconnectstructure 125 may comprise an interconnect member 127 extending throughthe second IMD layer 135 and a plurality of vias 128 extending throughthe first IMD layer 130 between the interconnect member 127 and one ormore of the conductive members 115.

The first and second IMD layers 130 and 135 may each comprise one ormore layers of silicon oxide, BLACK DIAMOND, and/or other materials,which may be formed by CVD, sputtering, spin-on coating, and/or otherprocesses. The first and second IMD layers 130 and 135 may each have athickness ranging between about 1500 angstroms and about 8000 angstroms,although other thicknesses are also within the scope of the presentdisclosure.

The interconnect member 127 and vias 128 may be formed in openings thatare defined in the first and second IMD layers 130 and 135 by applyingand developing one or more suitable photoresist layers (not shown), andthen etching the first and second IMD layers 130 and 135 to generate theopenings. The openings may be partially or substantially lined with abarrier layer (not shown) prior to formation of the interconnect member127 and/or vias 128. The barrier layer may comprise one or more layersof conductive and/or dielectric materials, such as titanium, titaniumnitride, tantalum nitride, titanium, silicon nitride, silicon oxide,and/or other materials, which may be formed utilizing CVD, PECVD, MOCVD,sputtering, and/or other processes.

The conductive material forming the interconnect member 127 and vias 128may comprise copper, aluminum, doped polysilicon, combinations thereof,and/or other materials, and may be formed by various CVD processes,perhaps including depositing a seed layer and then electroplating copperonto the seed layer. Grinding, CMP, and/or other processes may then beutilized to remove a portion of the conductive material to define theinterconnect member 127 flush with the upper surface 137 of the secondIMD layer 135.

The interconnect member 127 and vias 128 are depicted in FIG. 2 as beingthe result of a dual-damascene process, such that the vias 128 areformed integral to the interconnect member 127. However, in otherimplementations within the scope of the present disclosure, theinterconnect member 127 may be a discrete member, formed separate fromthe vias 128, yet still in electrical communication with the vias 128via direct contact and/or one or more intervening layers.

FIG. 3 is a cross-sectional view of a portion of the apparatus 100 shownin FIG. 2 in a subsequent stage of manufacture, in which a third IMDlayer 140 and a fourth IMD layer 145 have been formed over the existinglayers, and a through-silicon-via (TSV) opening 150 has been formed. Thethird and fourth IMD layers 140 and 145 may each comprise one or morelayers of silicon oxide, BLACK DIAMOND, and/or other materials, whichmay be formed by CVD, sputtering, spin-on coating, and/or otherprocesses. The third and fourth IMD layers 140 and 145 may each have athickness ranging between about 1500 angstroms and about 8000 angstroms,although other thicknesses are also within the scope of the presentdisclosure.

The TSV opening 150 may be formed by applying and developing a suitablephotoresist (not shown), and then etching to generate the TSV opening150. The TSV opening 150 may extend into the substrate 105, perhaps atleast further than any active and/or devices (not shown) formed in thesubstrate 105 and/or to a depth at least greater than the eventualdesired height of the finished semiconductor die. While the depth isdependent upon the overall design of the semiconductor die, the depthmay range between about 1 micron and about 700 microns below the surface107 of the substrate 105, such as to a depth of about 50 microns. TheTSV opening 150 may have a diameter D ranging between about 1 micron andabout 100 microns, such as a diameter of about 12 microns.

At least portions of the internal surfaces of the TSV opening 150 may belined with a TSV liner 155 comprising one or more layers of conductiveand/or dielectric materials, such as titanium, titanium nitride,tantalum nitride, titanium, silicon nitride, silicon oxide, and/or othermaterials, which may be formed utilizing CVD, PECVD, MOCVD, sputtering,and/or other processes. Grinding, CMP, and/or other processes may thenbe utilized to remove a portion of the TSV liner 155 to, for example, beflush with the surface 147 of the fourth IMD layer 145.

FIG. 4 is a cross-sectional view of a portion of the apparatus 100 shownin FIG. 3 in a subsequent stage of manufacture, in which the TSV opening150 has been at least partially lined with a TSV barrier layer 160, anda first portion of the TSV opening 150 has subsequently been filled witha first conductive material 165. The TSV barrier layer 160 may compriseone or more layers of conductive and/or dielectric materials, such astitanium, titanium nitride, tantalum nitride, titanium, silicon nitride,silicon oxide, and/or other materials, which may be formed utilizingCVD, PECVD, MOCVD, sputtering, and/or other processes. Grinding, CMP,and/or other processes may be utilized to remove a portion of the TSVbarrier layer 160.

The first conductive material 165 may comprise copper, aluminum, dopedpolysilicon, combinations thereof, and/or other materials, and may beformed by depositing a seed layer and then electroplating copper ontothe seed layer, among other deposition processes. As described above,only a portion of the TSV opening 150 is filled with the firstconductive material 165. The remaining portion of the TSV opening 150will be filled with a second conductive material substantiallysimultaneously with the formation of metallic features formed in thethird and fourth IMD layers 140 and 145. Thus, the upper surface of thefirst conductive material 165 may be about parallel or coplanar with theupper or lower surfaces of the third or fourth IMD layers 140 and 145,respectively.

FIG. 5 is a cross-sectional view of a portion of the apparatus 100 shownin FIG. 4 in a subsequent stage of manufacture, in which openings 170corresponding to an additional portion of the interconnect structure 125have been formed in the third and fourth IMD layers 140 and 145, and ametallization barrier layer 175 at least partially lines interiorsurfaces of the openings 170 and the remaining, unfilled portion of theTSV opening 150. The openings 170 may be defined in the third and fourthIMD layers 140 and 145 by applying and developing one or more suitablephotoresist layers (not shown), and then etching the third and fourthIMD layers 140 and 145 to generate the openings 170. The openings 170may extend to, expose, and/or “land on” the previously formedinterconnect member 127 of the interconnect structure 125.

The metallization barrier layer 175 may comprise one or more layers ofconductive and/or dielectric materials, such as titanium, titaniumnitride, tantalum nitride, titanium, silicon nitride, silicon oxide,and/or other materials, which may be formed utilizing CVD, PECVD, MOCVD,sputtering, and/or other processes. Grinding, CMP, and/or otherprocesses may be utilized to remove a portion of the metallizationbarrier layer 175.

FIG. 6 is a cross-sectional view of a portion of the apparatus 100 shownin FIG. 5 in a subsequent stage of manufacture, in which a secondconductive material 180 has been deposited in the openings 170 and theremaining unfilled portion of the TSV opening 150, thus substantiallysimultaneously forming an interconnect member in the openings 170 andcompleting the TSV structure in the TSV opening 150. The secondconductive material 180 may be substantially similar to the firstconductive material 165, such that the first and second conductivematerials 165 and 180 may be characterized by a common aspect resultingfrom being formed substantially simultaneously. For example, the firstand second conductive materials 165 and 180 may have substantially thesame material composition. Similarly, the first and second conductivematerials 165 and 180 may have substantially similar crystal structures,hardnesses, and/or densities. Other common aspects of the first andsecond conductive materials 165 and 180 may include one or more ofatomic mass/number/weight, compression, ductility, elasticity,electrical conductivity, etchant selectivity, malleability, magneticflux, tension, and/or thermal conductivity, among others.

The second conductive material 180 may be or comprise copper, aluminum,doped polysilicon, combinations thereof, and/or other materials, and maybe formed by various CVD processes, perhaps including depositing a seedlayer and then electroplating copper onto the seed layer. Grinding, CMP,and/or other processes may then be utilized to remove a portion of thesecond conductive material 180 to be flush with the upper surface 147 ofthe fourth IMD layer 145.

The interconnect member and vias formed by the second conductivematerial 180 are depicted in FIG. 6 as being the result of adual-damascene process, such that the vias are formed integral to theinterconnect member. However, in other implementations within the scopeof the present disclosure, the interconnect member may be a discretemember, formed separate from the vias, yet still in electricalcommunication with the vias via direct contact and/or one or moreintervening layers.

FIG. 7 is schematic view of at least a portion of an apparatus 700 in anintermediate stage of manufacture according to one or more aspects ofthe present disclosure. The apparatus 700 is fabricated from and/or on asubstrate 705, which may comprise bulk silicon, strained silicon,silicon germanium, and/or other materials. The substrate 705 may also beor comprise a silicon-on-insulator (SOI) substrate, such as asilicon-on-sapphire substrate, a silicon germanium-on-insulatorsubstrate, and/or another substrate comprising an epitaxialsemiconductor layer on an insulator layer. However, the substrate 705may comprise additional or alternative materials within the scope of thepresent disclosure. The substrate 705 may have a <100>, <110>, <111>, orother surface orientation. The substrate 705 may also comprise at leastportions of one or more active and/or passive devices (not shown), suchas transistors, capacitors, resistors, inductors, and/or other devicesthat may be utilized to generate the desired structural and functionalrequirements of the design. Such devices may be formed by any suitablemethods, whether within and/or on the surface of the substrate 705.

The apparatus 700 also comprises an interlayer dielectric (ILD) layer710 overlying at least portions of the substrate 705. The ILD layer 710may comprise one or more layers of silicon oxide, BLACK DIAMOND (aproduct of Applied Materials of Santa Clara, Calif.), and/or othermaterials, which may be formed by CVD, sputtering, spin-on coating,and/or other processes. The thickness of the ILD layer 710 may rangebetween about 1500 angstroms and about 8000 angstroms, although otherthicknesses are also within the scope of the present disclosure.

The apparatus 700 also comprises one or more conductive members 715extending through the thickness of the ILD layer 710. The conductivemembers 715 may be formed in openings that are defined in the ILD layer710 by applying and developing a suitable photoresist (not shown), andthen etching the ILD layer 715 to generate the openings. The openingsfor the conductive members 715 may be partially or substantially linedwith a barrier layer (not shown) prior to formation of the conductivemembers 715. The barrier layer may comprise one or more layers ofconductive and/or dielectric materials, such as titanium, titaniumnitride, tantalum nitride, titanium, silicon nitride, silicon oxide,and/or other materials, which may be formed utilizing CVD, PECVD, MOCVD,sputtering, and/or other processes.

The conductive material forming the conductive members 715 may comprisecopper, aluminum, doped polysilicon, combinations thereof, and/or othermaterials, and may be formed by various CVD processes, perhaps includingdepositing a seed layer and then electroplating copper onto the seedlayer. Grinding, chemical mechanical planarizing (CMP), and/or otherprocesses may then be utilized to remove a portion of the conductivematerial to define the conductive members 715 flush with the uppersurface 712 of the ILD layer 710.

The conductive members 715 may each extend through the ILD layer 710 tothe substrate 705 and/or to a corresponding feature 720 formed on and/orin the substrate 705. For example, the feature 720 may comprise alanding pad, a bond pad, a trace, a contact of one or more active and/orpassive devices, and/or other conductive elements.

FIG. 8 is a cross-sectional view of a portion of the apparatus 700 shownin FIG. 7 in a subsequent stage of manufacture, in which a portion of aninterconnect structure 800 has been formed in a first IMD layer 730. Theinterconnect structure 800 may comprise a plurality of vias 805extending through the first IMD layer 730 to one or more of theconductive members 715.

The first IMD layer 730 may comprise one or more layers of siliconoxide, BLACK DIAMOND, and/or other materials, which may be formed byCVD, sputtering, spin-on coating, and/or other processes. The first IMDlayer 730 may have a thickness ranging between about 1500 angstroms andabout 8000 angstroms, although other thicknesses are also within thescope of the present disclosure.

The vias 805 may be formed in openings that are defined in the first IMDlayer 730 by applying and developing one or more suitable photoresistlayers (not shown), and then etching the first IMD layer 730 to generatethe openings. The openings may be partially or substantially lined witha barrier layer (not shown) prior to formation of the vias 805. Thebarrier layer may comprise one or more layers of conductive and/ordielectric materials, such as titanium, titanium nitride, tantalumnitride, titanium, silicon nitride, silicon oxide, and/or othermaterials, which may be formed utilizing CVD, PECVD, MOCVD, sputtering,and/or other processes.

The conductive material forming the vias 805 may comprise copper,aluminum, doped polysilicon, combinations thereof, and/or othermaterials, and may be formed by various CVD processes, perhaps includingdepositing a seed layer and then electroplating copper onto the seedlayer. Grinding, CMP, and/or other processes may then be utilized toremove a portion of the conductive material to define the vias 805 flushwith the upper surface 732 of the first IMD layer 730.

FIG. 9 is a cross-sectional view of a portion of the apparatus 700 shownin FIG. 8 in a subsequent stage of manufacture, in which another portionof the interconnect structure 800 has been formed in a second IMD layer735. For example, the interconnect structure 800 may comprise aninterconnect member 810 extending through the second IMD layer 735 tothe plurality of vias 805 that extend through the first IMD layer 730.

The second IMD layer 735 may comprise one or more layers of siliconoxide, BLACK DIAMOND, and/or other materials, which may be formed byCVD, sputtering, spin-on coating, and/or other processes. The second IMDlayer 735 may have a thickness ranging between about 1500 angstroms andabout 8000 angstroms, although other thicknesses are also within thescope of the present disclosure.

The interconnect member 810 may be formed in an opening that is definedin the second IMD layer 735 by applying and developing one or moresuitable photoresist layers (not shown), and then etching the second IMDlayer 735 to generate the opening. The opening may be partially orsubstantially lined with a barrier layer (not shown) prior to formationof the interconnect member 810. The barrier layer may comprise one ormore layers of conductive and/or dielectric materials, such as titanium,titanium nitride, tantalum nitride, titanium, silicon nitride, siliconoxide, and/or other materials, which may be formed utilizing CVD, PECVD,MOCVD, sputtering, and/or other processes.

The conductive material forming the interconnect member 810 may comprisecopper, aluminum, doped polysilicon, combinations thereof, and/or othermaterials, and may be formed by various CVD processes, perhaps includingdepositing a seed layer and then electroplating copper onto the seedlayer. Grinding, CMP, and/or other processes may then be utilized toremove a portion of the conductive material to define the interconnectmember 810 flush with the upper surface 737 of the second IMD layer 735.

FIG. 10 is a cross-sectional view of a portion of the apparatus 700shown in FIG. 9 in a subsequent stage of manufacture, in which anotherportion of the interconnect structure 800 has been formed in a third IMDlayer 740. For example, the interconnect structure 800 may compriseanother plurality of vias 815 extending through the third IMD layer 740to the underlying conductive member 810.

The third IMD layer 740 may comprise one or more layers of siliconoxide, BLACK DIAMOND, and/or other materials, which may be formed byCVD, sputtering, spin-on coating, and/or other processes. The third IMDlayer 740 may have a thickness ranging between about 1500 angstroms andabout 8000 angstroms, although other thicknesses are also within thescope of the present disclosure.

The vias 815 may be formed in openings that are defined in the third IMDlayer 740 by applying and developing one or more suitable photoresistlayers (not shown), and then etching the third IMD layer 740 to generatethe openings. The openings may be partially or substantially lined witha barrier layer (not shown) prior to formation of the vias 815. Thebarrier layer may comprise one or more layers of conductive and/ordielectric materials, such as titanium, titanium nitride, tantalumnitride, titanium, silicon nitride, silicon oxide, and/or othermaterials, which may be formed utilizing CVD, PECVD, MOCVD, sputtering,and/or other processes.

The conductive material forming the vias 815 may comprise copper,aluminum, doped polysilicon, combinations thereof, and/or othermaterials, and may be formed by various CVD processes, perhaps includingdepositing a seed layer and then electroplating copper onto the seedlayer. Grinding, CMP, and/or other processes may then be utilized toremove a portion of the conductive material to define the vias 738 flushwith the upper surface 742 of the third IMD layer 740.

FIG. 11 is a cross-sectional view of a portion of the apparatus 700shown in FIG. 10 in a subsequent stage of manufacture, in which anotherportion of the interconnect structure 800 has been formed in a fourthIMD layer 745. For example, the interconnect structure 800 may comprisean interconnect member 820 extending through the fourth IMD layer 745 tothe plurality of vias 815 that extend through the third IMD layer 740.

The fourth IMD layer 745 may comprise one or more layers of siliconoxide, BLACK DIAMOND, and/or other materials, which may be formed byCVD, sputtering, spin-on coating, and/or other processes. The fourth IMDlayer 745 may have a thickness ranging between about 1500 angstroms andabout 8000 angstroms, although other thicknesses are also within thescope of the present disclosure.

The interconnect member 820 may be formed in an opening that is definedin the fourth IMD layer 745 by applying and developing one or moresuitable photoresist layers (not shown), and then etching the fourth IMDlayer 745 to generate the opening. The opening may be partially orsubstantially lined with a barrier layer (not shown) prior to formationof the interconnect member 820. The barrier layer may comprise one ormore layers of conductive and/or dielectric materials, such as titanium,titanium nitride, tantalum nitride, titanium, silicon nitride, siliconoxide, and/or other materials, which may be formed utilizing CVD, PECVD,MOCVD, sputtering, and/or other processes.

The conductive material forming the interconnect member 820 may comprisecopper, aluminum, doped polysilicon, combinations thereof, and/or othermaterials, and may be formed by various CVD processes, perhaps includingdepositing a seed layer and then electroplating copper onto the seedlayer. Grinding, CMP, and/or other processes may then be utilized toremove a portion of the conductive material to define the interconnectmember 820 flush with the upper surface 747 of the fourth IMD layer 745.

FIG. 12 is a cross-sectional view of a portion of the apparatus 700shown in FIG. 11 in a subsequent stage of manufacture, in which anotherportion of the interconnect structure 800 has been formed in a fifth IMDlayer 750. For example, the interconnect structure 800 may compriseadditional vias 825 extending through the fifth IMD layer 750 to one ormore of the underlying conductive members 820.

The fifth IMD layer 750 may comprise one or more layers of siliconoxide, BLACK DIAMOND, and/or other materials, which may be formed byCVD, sputtering, spin-on coating, and/or other processes. The fifth IMDlayer 750 may have a thickness ranging between about 1500 angstroms andabout 8000 angstroms, although other thicknesses are also within thescope of the present disclosure.

The vias 825 may be formed in openings that are defined in the fifth IMDlayer 750 by applying and developing one or more suitable photoresistlayers (not shown), and then etching the fifth IMD layer 750 to generatethe openings. The openings may be partially or substantially lined witha barrier layer (not shown) prior to formation of the vias 825. Thebarrier layer may comprise one or more layers of conductive and/ordielectric materials, such as titanium, titanium nitride, tantalumnitride, titanium, silicon nitride, silicon oxide, and/or othermaterials, which may be formed utilizing CVD, PECVD, MOCVD, sputtering,and/or other processes.

The conductive material forming the vias 825 may comprise copper,aluminum, doped polysilicon, combinations thereof, and/or othermaterials, and may be formed by various CVD processes, perhaps includingdepositing a seed layer and then electroplating copper onto the seedlayer. Grinding, CMP, and/or other processes may then be utilized toremove a portion of the conductive material to define the vias 825 flushwith the upper surface 752 of the fifth IMD layer 750.

FIG. 13 is a cross-sectional view of a portion of the apparatus 700shown in FIG. 12 in a subsequent stage of manufacture, in which anotherportion of the interconnect structure 800 has been formed in a sixth IMDlayer 755. For example, the interconnect structure 800 may comprise aninterconnect member 830 extending through the sixth IMD layer 755 to theplurality of vias 825 that extend through the fifth IMD layer 750.

The sixth IMD layer 755 may comprise one or more layers of siliconoxide, BLACK DIAMOND, and/or other materials, which may be formed byCVD, sputtering, spin-on coating, and/or other processes. The sixth IMDlayer 755 may have a thickness ranging between about 1500 angstroms andabout 8000 angstroms, although other thicknesses are also within thescope of the present disclosure.

The interconnect member 830 may be formed in an opening that is definedin the sixth IMD layer 755 by applying and developing one or moresuitable photoresist layers (not shown), and then etching the sixth IMDlayer 755 to generate the opening. The opening may be partially orsubstantially lined with a barrier layer (not shown) prior to formationof the interconnect member 830. The barrier layer may comprise one ormore layers of conductive and/or dielectric materials, such as titanium,titanium nitride, tantalum nitride, titanium, silicon nitride, siliconoxide, and/or other materials, which may be formed utilizing CVD, PECVD,MOCVD, sputtering, and/or other processes.

The conductive material forming the interconnect member 830 may comprisecopper, aluminum, doped polysilicon, combinations thereof, and/or othermaterials, and may be formed by various CVD processes, perhaps includingdepositing a seed layer and then electroplating copper onto the seedlayer. Grinding, CMP, and/or other processes may then be utilized toremove a portion of the conductive material to define the interconnectmember 830 flush with the upper surface 757 of the sixth IMD layer 755.

FIG. 14 is a cross-sectional view of a portion of the apparatus 700shown in FIG. 13 in a subsequent stage of manufacture, in which anotherportion of the interconnect structure 800 has been formed in a seventhIMD layer 760. For example, the interconnect structure 800 may compriseadditional vias 835 extending through the seventh IMD layer 760 to oneor more of the underlying conductive members 830.

The seventh IMD layer 760 may comprise one or more layers of siliconoxide, BLACK DIAMOND, and/or other materials, which may be formed byCVD, sputtering, spin-on coating, and/or other processes. The seventhIMD layer 760 may have a thickness ranging between about 1500 angstromsand about 8000 angstroms, although other thicknesses are also within thescope of the present disclosure.

The vias 835 may be formed in openings that are defined in the seventhIMD layer 760 by applying and developing one or more suitablephotoresist layers (not shown), and then etching the seventh IMD layer760 to generate the openings. The openings may be partially orsubstantially lined with a barrier layer (not shown) prior to formationof the vias 835. The barrier layer may comprise one or more layers ofconductive and/or dielectric materials, such as titanium, titaniumnitride, tantalum nitride, titanium, silicon nitride, silicon oxide,and/or other materials, which may be formed utilizing CVD, PECVD, MOCVD,sputtering, and/or other processes.

The conductive material forming the vias 835 may comprise copper,aluminum, doped polysilicon, combinations thereof, and/or othermaterials, and may be formed by various CVD processes, perhaps includingdepositing a seed layer and then electroplating copper onto the seedlayer. Grinding, CMP, and/or other processes may then be utilized toremove a portion of the conductive material to define the vias 835 flushwith the upper surface 762 of the seventh IMD layer 760.

FIG. 15 is a cross-sectional view of a portion of the apparatus 700shown in FIG. 14 in a subsequent stage of manufacture, in which aneighth IMD layer 765 has been formed over the existing layers, and a TSVopening 900 has been formed. The eighth IMD layer 765 may comprise oneor more layers of silicon oxide, BLACK DIAMOND, and/or other materials,which may be formed by CVD, sputtering, spin-on coating, and/or otherprocesses, perhaps to a thickness ranging between about 1500 angstromsand about 8000 angstroms, although other thicknesses are also within thescope of the present disclosure.

The TSV opening 900 may be formed by applying and developing a suitablephotoresist (not shown), and then etching to generate the TSV opening150. The TSV opening 900 may extend into the substrate 705, perhaps atleast further than any active and/or devices (not shown) formed in thesubstrate 705 and/or to a depth at least greater than the eventualdesired height of the finished semiconductor die. While the depth isdependent upon the overall design of the semiconductor die, the depthmay range between about 1 micron and about 700 microns below the surface707 of the substrate 705, such as to a depth of about 50 microns. TheTSV opening 900 may have a diameter ranging between about 1 micron andabout 100 microns, such as a diameter of about 12 microns.

At least portions of the internal surfaces of the TSV opening 900 may belined with a TSV liner 905 comprising one or more layers of conductiveand/or dielectric materials, such as titanium, titanium nitride,tantalum nitride, titanium, silicon nitride, silicon oxide, and/or othermaterials, which may be formed utilizing CVD, PECVD, MOCVD, sputtering,and/or other processes. Grinding, CMP, and/or other processes may thenbe utilized to remove a portion of the TSV liner 905 to, for example, beflush with the surface 767 of the eighth IMD layer 765.

The apparatus 700 may comprise a TSV barrier layer 910 at leastpartially covering the internal surfaces of the TSV liner 905. A firstportion of the TSV opening 900 may then be filled with a firstconductive material 915. The TSV barrier layer 910 may comprise one ormore layers of conductive and/or dielectric materials, such as titanium,titanium nitride, tantalum nitride, titanium, silicon nitride, siliconoxide, and/or other materials, which may be formed utilizing CVD, PECVD,MOCVD, sputtering, and/or other processes. Grinding, CMP, and/or otherprocesses may be utilized to remove a portion of the TSV barrier layer910.

The first conductive material 915 may comprise copper, aluminum, dopedpolysilicon, combinations thereof, and/or other materials, and may beformed by depositing a seed layer and then electroplating copper ontothe seed layer, among other deposition processes. As described above,only a portion of the TSV opening 900 is filled with the firstconductive material 915. The remaining portion of the TSV opening 900will be filled with a second conductive material substantiallysimultaneously with the formation of metallic features formed in theeighth IMD layer 765. Thus, the upper surface of the first conductivematerial 915 may be about parallel or coplanar with the upper or lowersurfaces of the seventh or eighth IMD layers 760 and 765, respectively.

FIG. 16 is a cross-sectional view of a portion of the apparatus 700shown in FIG. 15 in a subsequent stage of manufacture, in which anopening 768 corresponding to an additional portion of the interconnectstructure 800 has been formed in the eighth IMD layer 765, andmetallization barrier layers 840 and 920 at least partially lineinterior surfaces of the opening 768 and the remaining, unfilled portionof the TSV opening 900. The opening 768 may be defined in the eighth IMDlayer 765 by applying and developing one or more suitable photoresistlayers (not shown), and then etching the eighth IMD layer 765 togenerate the opening 768. The opening 768 may extend to, expose, and/or“land on” one or more of the previously formed vias 835 of theinterconnect structure 800.

The metallization barrier layers 840 and 920 may each comprise one ormore layers of conductive and/or dielectric materials, such as titanium,titanium nitride, tantalum nitride, titanium, silicon nitride, siliconoxide, and/or other materials, which may be formed utilizing CVD, PECVD,MOCVD, sputtering, and/or other processes. Grinding, CMP, and/or otherprocesses may be utilized to remove a portion of metallization barrierlayers 840 and 920 so that they are substantially flush with the surface767 of the eighth IMD layer 765.

FIG. 17 is a cross-sectional view of a portion of the apparatus 700shown in FIG. 16 in a subsequent stage of manufacture, in which a secondconductive material 925 has been deposited in the opening 768 and theremaining unfilled portion of the TSV opening 900, thus substantiallysimultaneously forming an interconnect member in the opening 768 andcompleting the TSV structure in the TSV opening 900. The secondconductive material 925 may be substantially similar to the firstconductive material 915, such that the first and second conductivematerials 915 and 925 may be characterized by a common aspect resultingfrom being formed substantially simultaneously. For example, the firstand second conductive materials 915 and 925 may have substantially thesame material composition. Similarly, the first and second conductivematerials 915 and 925 may have substantially similar crystal structures,hardnesses, and/or densities. Other common aspects of the first andsecond conductive materials 915 and 925 may include one or more ofatomic mass/number/weight, compression, ductility, elasticity,electrical conductivity, etchant selectivity, malleability, magneticflux, tension, and/or thermal conductivity, among others.

The second conductive material 925 may be or comprise copper, aluminum,doped polysilicon, combinations thereof, and/or other materials, and maybe formed by various CVD processes, perhaps including depositing a seedlayer and then electroplating copper onto the seed layer. Grinding, CMP,and/or other processes may then be utilized to remove a portion of thesecond conductive material 925 to be flush with the upper surface 767 ofthe eighth IMD layer 765.

As described above, the second conductive material 180 utilized tocomplete the TSV structure in the implementation depicted in FIGS. 1-6may be deposited substantially simultaneously with the metallizationutilized to form the second dual-damascene structure within the thirdand fourth IMD layers 140 and 145. Similarly, the second conductivematerial 925 utilized to complete the TSV structure in theimplementation depicted in FIGS. 7-17 may be deposited substantiallysimultaneously with the metallization utilized to form the interconnectmember within the eighth IMD layer 765. However, other implementationswithin the scope of the present disclosure may entail depositing theupper portion of the TSV structure substantially simultaneously with anystage of metal layer. Thus, for example, the upper portion of the TSVstructure may be formed substantially simultaneously with the “Nth”metal layer in implementations utilizing “X” metallization layers,wherein N and X are integers, and wherein X is equal or greater to N.

The example implementations described above include those in which theinterconnect features comprise dual-damascene structures formed in dualdielectric layers separated by an etch stop layer. However, otherimplementations of the interconnect features within the scope of thepresent disclosure may also comprise dual-damascene structures formed ina single dielectric layer, with no etch stop layer, such as may be knownas a timed etch process.

For example, FIG. 18 is a sectional view of a portion of apparatus 300in an intermediate stage of manufacture according to one or more aspectsof the present disclosure. The apparatus 300 may have one or moreaspects in common with the apparatus 100 shown in FIGS. 1-6 and/or theapparatus 700 shown in FIGS. 7-17. The apparatus 300 includes adielectric layer 310 in which a dual-damascene feature will bemanufactured. The dielectric layer 310 may be an ILD layer, an IMDlayer, and/or other layer formed over a substrate 320, perhaps with oneor more intervening layers 330. The dielectric layer 310 may comprisesilicon oxide, BLACK DIAMOND, and/or other materials, which may beformed by CVD, sputtering, spin-on coating, and/or other processes. Thedielectric layer 310 may have a thickness ranging between about 1500angstroms and about 8000 angstroms, although other thicknesses are alsowithin the scope of the present disclosure.

As also depicted in FIG. 18, a first photoresist layer 340 may beutilized during a first timed etch process to remove a portion of thethickness T of the dielectric layer 310. Thus, an opening 350 may beformed in an upper (relative to the page) portion of the dielectriclayer 310. The opening 350 may have lateral dimensions proportional toor otherwise corresponding to the interconnect member that will beformed therein.

FIG. 19 is a sectional view of the apparatus 300 shown in FIG. 18 in asubsequent stage of manufacture, in which a second photoresist layer 360has been utilized during a second timed etch process to remove theremaining thickness of the dielectric layer 310. However, the secondphotoresist layer 360 partially fills the opening 350, such that only aportion of the opening 350 is extended to the underlying layer 330.

FIG. 20 is a sectional view of the apparatus 300 shown in FIG. 19 in asubsequent stage of manufacture, in which the second photoresist layer360 has been removed to reveal the stepped opening, which is then filledwith a conductive material to form the dual-damascene structure 370. Thedual-damascene structure 370 may form an interconnect featuresubstantially similar to those described above. For example, thedual-damascene structure 370 may form an interconnect feature comprisingan interconnect member 372 and one or more vias 374.

The conductive material forming the dual-damascene structure 370comprise copper, aluminum, doped polysilicon, combinations thereof,and/or other materials, and may be formed by various CVD processes,perhaps including depositing a seed layer and then electroplating copperonto the seed layer. Grinding, CMP, and/or other processes may then beutilized to remove a portion of the conductive material to define thedual-damascene structure 370 flush with the upper surface 312 of thedielectric layer 310.

The opening 350 may be partially or substantially lined with a barrierlayer (not shown) prior to formation of the dual-damascene structure370. Such barrier layer may comprise one or more layers of conductiveand/or dielectric materials, such as titanium, titanium nitride,tantalum nitride, titanium, silicon nitride, silicon oxide, and/or othermaterials, which may be formed utilizing CVD, PECVD, MOCVD, sputtering,and/or other processes.

FIG. 21 is a sectional view of a portion of apparatus 400 in anintermediate stage of manufacture according to one or more aspects ofthe present disclosure. The apparatus 400 may have one or more aspectsin common with the apparatus 100 shown in FIGS. 1-6, the apparatus 700shown in FIGS. 7-17, and/or the apparatus 300 shown in FIGS. 18-20.However, one or more of the metal layers of the interconnect structuredescribed in the example implementations above may not be formed withina series of dielectric layers, but may instead be formed in other formsof dielectric material. One such example implementation, depicted inFIG. 21, entails the utilization of a volume of dielectric gas 410 asthe dielectric material in which the one or more metal layers 420 areformed. The dielectric gas may substantially comprise air, nitrogen,sulfur hexafluoride, and/or other gases able to provide electricalisolation.

In such implementations, the metal layers 420 may be formed via one ormore of the processed described above, followed by a selective etchingprocess to remove the dielectric layers. Alternatively, or additionally,the metal layers 420 may be formed via atomic layer deposition and/orother atomic- and/or molecular-level deposition techniques. Suchprocesses may utilize various photolithography masks similar to thosedescribed above.

One skilled in the art will recognize that in the embodimentsillustrated in FIGS. 18-21, a TSV structure, similar to the structureillustrated in FIGS. 1-17, can be formed laterally offset from theillustrated interconnect feature and a portion of the TSV structure canbe formed substantially simultaneously with forming of the interconnectmember.

In view of the entirety of the present disclosure, including thefigures, a person having ordinary skill in the art will readilyrecognize that the present disclosure introduces a method comprising:forming an interconnect structure comprising a plurality of interconnectfeatures disposed in dielectric material over a substrate, wherein eachof the plurality of interconnect features comprises an interconnectmember and a via extending between the interconnect member and aconductive member formed within the dielectric material; and forming athrough-silicon-via (TSV) structure laterally offset from theinterconnect structure by: forming a first portion of the TSV structurewith a first conductive material; and forming a second portion of theTSV structure with a second conductive material; wherein forming thesecond portion of the TSV structure occurs substantially simultaneouslywith forming one of the plurality of interconnect features.

The dielectric material may comprise a plurality of dielectric layersformed over the substrate. At least one of the plurality of interconnectfeatures may extend through no more than one of the plurality ofdielectric layers. For at least one of the plurality of interconnectfeatures: the interconnect member may extend through a first one of theplurality of dielectric layers; the via may extend through a second oneof the plurality of dielectric layers between the interconnect memberand the conductive member; and the conductive member may extend througha third one of the plurality of dielectric layers. The third one of theplurality of dielectric layers may be disposed between the substrate andthe second one of the plurality of dielectric layers. The second one ofthe plurality of dielectric layers may be disposed between the third oneof the dielectric layers and the first one of the plurality ofdielectric layers. The second and third ones of the plurality ofdielectric layers may be disposed between the substrate and the firstone of the plurality of dielectric layers. Forming the interconnectstructure may further comprise forming first and second barrier layerssubstantially simultaneously, including: forming the first barrier layeralong internal surfaces of at least one opening defined in at least oneof the plurality of dielectric layers; and forming the second barrierlayer along a surface of the first conductive material.

Each interconnect member may be formed as a portion of one of aplurality of metal layers formed in the dielectric material, where theplurality of metal layers may include at least a first metal layer, asecond metal layer, and a third metal layer, and the second portion ofthe TSV structure may be formed with the second conductive materialsubstantially simultaneously with forming the second metal layer.

Each interconnect member may be formed as a portion of one of aplurality of metal layers formed in the dielectric material, where theplurality of metal layers may include at least a first metal layer, asecond metal layer, and a third metal layer, and the second portion ofthe TSV structure may be formed with the second conductive materialsubstantially simultaneously with forming one of the plurality of metallayers other than the second metal layer.

The dielectric material may substantially comprise a volume ofdielectric gas. The dielectric gas may substantially comprise air.

The interconnect member and corresponding via of at least one of theplurality of interconnect features may comprise a dual-damascenestructure.

The first and second conductive materials may have substantially thesame composition.

Forming the TSV structure may further comprise forming a TSV liner alonginternal surfaces of a TSV opening prior to forming the first portion ofthe TSV structure within the TSV opening.

The present disclosure also introduces a method comprising: forming afirst dielectric layer over a substrate; forming a plurality ofelectrically conductive plugs extending through the first dielectriclayer; forming a second dielectric layer over the first dielectric layerand the plugs; forming a third dielectric layer over the seconddielectric layer; forming a first dual-damascene structure comprising: afirst interconnect extending through the third dielectric layer; and afirst plurality of vias extending through the second dielectric layerbetween the first interconnect and the plugs; forming a fourthdielectric layer over the third dielectric layer and the firstinterconnect; forming a fifth dielectric layer over the fourthdielectric layer; forming a second dual-damascene structure comprising:a second interconnect extending through the fifth dielectric layer; anda second plurality of vias extending through the fourth dielectric layerbetween the second interconnect and the first interconnect; and forminga through-silicon-via (TSV) structure laterally offset from the firstand second interconnects by: forming a recess extending through thefirst, second, third, fourth, and fifth dielectric layers and into thesubstrate; filling a first portion of the recess with a first conductivematerial; and filling a second portion of the recess with a secondconductive material; wherein forming the second portion of the recesswith the second conductive materials occurs substantially simultaneouslywith forming one of the first and second dual-damascene structures. Thefirst and second conductive materials may have substantially the samecomposition. Forming the TSV structure may further comprise forming aTSV liner along internal surfaces of the recess prior to filling thefirst portion of the recess with the first conductive material. Suchmethod may further comprise forming first and second barrier layerssubstantially simultaneously, including: forming the first barrier layeralong internal surfaces of at least one opening defined in at least oneof the first, second, third, fourth, and fifth dielectric layers; andforming the second barrier layer along a surface of the first conductivematerial.

The present disclosure also introduces an apparatus comprising: aninterconnect structure comprising a plurality of interconnect featuresdisposed in dielectric material over a substrate, wherein each of theplurality of interconnect features comprises an interconnect member anda via extending between the interconnect member and a conductive memberformed within the dielectric material; and a through-silicon-via (TSV)structure laterally offset from the interconnect structure andcomprising: a first portion extending into the substrate; and a secondportion; wherein the second portion of the TSV structure and at leastone of the interconnect members are collectively characterized by anaspect resulting from being formed substantially simultaneously.

The dielectric material may comprise a plurality of dielectric layers.At least one of the plurality of interconnect features may extendthrough no more than one of the plurality of dielectric layers. For atleast one of the plurality of interconnect features: the interconnectmember may extend through a first one of the plurality of dielectriclayers; the via may extend through a second one of the plurality ofdielectric layers; and the conductive member may extend through a thirdone of the plurality of dielectric layers. The first portion of the TSVstructure may extend through at least one of the plurality of dielectriclayers, and the second portion of the TSV structure may extend from thefirst portion through each of the plurality of dielectric layers notpenetrated by the first portion.

At least one of the plurality of interconnect features may comprise adual-damascene structure.

The aspect may be material composition.

The TSV structure may further comprise a TSV liner disposed between thefirst portion and the substrate.

The interconnect structure may further comprise: a first barrier layerformed along internal surfaces of at least one opening defined in thedielectric material; and a second barrier layer between the first andsecond portions of the TSV structure; wherein the first and secondbarrier layers may be collectively characterized by an aspect resultingfrom being formed substantially simultaneously.

The present disclosure also introduces a method comprising: (1) formingan interconnect structure comprising a plurality of interconnectfeatures disposed in corresponding ones of a plurality of dielectriclayers formed over a substrate, wherein forming each of the plurality ofinterconnect features comprises: (a) forming an interconnect memberextending through a first one of the plurality of dielectric layers; and(b) forming a plurality of vias within a second one of the plurality ofdielectric layers and extending between the interconnect member and oneor more conductive members formed within a third one of the plurality ofdielectric layers; and (2) forming a through-silicon-via (TSV) structurelaterally offset from the interconnect structure by: (a) forming a TSVopening; (b) filling a first portion of the TSV opening with a firstconductive material; and (c) filling a second portion of the TSV openingwith a second conductive material; wherein filling the second portion ofthe TSV opening occurs substantially simultaneously with forming one ofthe plurality interconnects.

At least one of the plurality of interconnect features may comprise adual-damascene structure comprising ones of the plurality of vias formedintegral to the corresponding interconnect member.

The third one of the plurality of dielectric layers may be disposedbetween the substrate and the second one of the plurality of dielectriclayers.

The second one of the plurality of dielectric layers may be disposedbetween the third one of the dielectric layers and the first one of theplurality of dielectric layers.

The second and third ones of the plurality of dielectric layers may bedisposed between the substrate and the first one of the plurality ofdielectric layers.

The first and second conductive materials may have substantially thesame composition.

A closest one of the plurality of dielectric layers, relative to thesubstrate, may be an interlayer dielectric layer comprising tungstenplugs.

Forming the TSV structure may further comprise forming a TSV liner alonginternal surfaces of the TSV opening prior to filling the first portionof the TSV opening with the first conductive material. Forming theinterconnect structure may further comprise forming first and secondbarrier layers substantially simultaneously, including: (i) forming thefirst barrier layer along internal surfaces of at least one openingdefined in at least one of the plurality of dielectric layers; and (ii)forming the second barrier layer along a surface of the first conductivematerial.

Each interconnect member may be formed as a portion of one of aplurality of metal layers formed in corresponding ones of the pluralityof dielectric layers, and the plurality of metal layers may include atleast a first metal layer, a second metal layer, and a third metallayer, in which case the second portion of the TSV opening may be filledwith the second conductive material substantially simultaneously withforming the second metal layer.

Each interconnect member may be formed as a portion of one of aplurality of metal layers formed in corresponding ones of the pluralityof dielectric layers, and the plurality of metal layers may include atleast a first metal layer, a second metal layer, and a third metallayer, in which case the second portion of the TSV opening may be filledwith the second conductive material substantially simultaneously withforming one of the plurality of metal layers other than the second metallayer.

The present disclosure also introduces a method comprising: (1) forminga first dielectric layer over a substrate; (2) forming a plurality ofelectrically conductive plugs extending through the first dielectriclayer; (3) forming a second dielectric layer over the first dielectriclayer and the plugs; (4) forming a third dielectric layer over thesecond dielectric layer; (5) forming a first dual-damascene structurecomprising: (a) a first interconnect extending through the thirddielectric layer; and (b) a first plurality of vias extending throughthe second dielectric layer between the first interconnect and theplugs; (6) forming a fourth dielectric layer over the third dielectriclayer and the first interconnect; (7) forming a fifth dielectric layerover the fourth dielectric layer; (8) forming a second dual-damascenestructure comprising: (a) a second interconnect extending through thefifth dielectric layer; and (b) a second plurality of vias extendingthrough the fourth dielectric layer between the second interconnect andthe first interconnect; and (9) forming a through-silicon-via (TSV)structure laterally offset from the first and second interconnects by:(a) forming a recess extending through the first, second, third, fourth,and fifth dielectric layers and into the substrate; (b) filling a firstportion of the recess with a first conductive material; and (c) fillinga second portion of the recess with a second conductive material;wherein forming the second portion of the recess with the secondconductive materials occurs substantially simultaneously with formingone of the first and second dual-damascene structures. The first andsecond conductive materials may have substantially the same composition.Forming the TSV structure may further comprise forming a TSV liner alonginternal surfaces of the recess prior to filling the first portion ofthe recess with the first conductive material. The method may furthercomprise forming first and second barrier layers substantiallysimultaneously, including: (i) forming the first barrier layer alonginternal surfaces of at least one opening defined in at least one of thefirst, second, third, fourth, and fifth dielectric layers; and (ii)forming the second barrier layer along a surface of the first conductivematerial.

The present disclosure also introduces an apparatus comprising: (1) aninterconnect structure comprising a plurality of interconnect featuresdisposed in corresponding ones of a plurality of dielectric layersformed over a substrate, wherein each of the plurality of interconnectfeatures comprises: (a) an interconnect member; and (b) a via extendingbetween the interconnect member and a conductive member formed withinthe dielectric material; (2) a through-silicon-via (TSV) structurelaterally offset from the interconnect structure and comprising: (a) afirst portion extending into the substrate; and (b) a second portion;and (3) a barrier layer extending between each of the plurality ofinterconnect features and the dielectric material and between the firstand second portions of the TSV structure.

The dielectric material may comprise a plurality of dielectric layers.At least one of the plurality of interconnect features may extendthrough no more than one of the plurality of dielectric layers. For atleast one of the plurality of interconnect features: (1) theinterconnect member may extend through a first one of the plurality ofdielectric layers; (2) the via may extend through a second one of theplurality of dielectric layers; and (3) the conductive member may extendthrough a third one of the plurality of dielectric layers. The firstportion of the TSV structure may extend through at least one of theplurality of dielectric layers, and the second portion of the TSVstructure may extend from the first portion through each of theplurality of dielectric layers not penetrated by the first portion.

At least one of the plurality of interconnect features may comprise adual-damascene structure comprising ones of the plurality of vias formedintegral to the corresponding interconnect member.

The TSV structure may further comprise a TSV liner disposed between thefirst portion and the substrate.

The barrier layer may be formed along internal surfaces of at least oneopening defined in the dielectric material.

The present disclosure also introduces a semiconductor structureincluding: an interconnect structure comprising a plurality ofinterconnect features disposed in a dielectric material over asubstrate, where a first interconnect feature of the plurality ofinterconnect features comprises a conductive line and a conductive via;and a through-silicon-via (TSV) structure laterally offset from theinterconnect structure, the TSV structure including: a first conductivelayer extending into the substrate; a second conductive layer over thefirst conductive layer; and a first barrier layer extending between thefirst conductive layer and the second conductive layer, where aninterface between the conductive line and the conductive via issubstantially level with an interface between the first conductive layerand the first barrier layer.

The present disclosure also introduces a semiconductor structureincluding: a substrate; a dielectric material over the substrate; aconductive interconnect within the dielectric material, the conductiveinterconnect including a conductive line and a conductive via; and athrough-silicon-via (TSV) structure laterally spaced apart from theconductive interconnect, the TSV structure extending through thedielectric material and into the substrate, the TSV structure including:a first conductive layer extending into the substrate; a secondconductive layer over the first conductive layer; and a first barrierlayer extending between the first conductive layer and the secondconductive layer, where a thickness of the conductive line issubstantially same as a combined thickness of the first barrier layerand the second conductive layer.

The present disclosure also introduces a semiconductor structureincluding: a substrate; a first dielectric layer over the substrate; asecond dielectric layer over the first dielectric layer; adual-damascene interconnect extending through the first dielectric layerand the second dielectric layer, the dual-damascene interconnectincluding: a conductive via within the first dielectric layer; and aconductive line within the second dielectric layer; and athrough-silicon-via (TSV) structure laterally spaced apart from thedual-damascene interconnect, the TSV structure including: a firstconductive layer extending through the first dielectric layer and intothe substrate; a second conductive layer within the second dielectriclayer; and a first barrier layer extending between the first conductivelayer and the second conductive layer, where a thickness of the seconddielectric layer is substantially same as a combined thickness of thefirst barrier layer and the second conductive layer.

The foregoing outlines features of several embodiments so that a personhaving ordinary skill in the art may better understand the aspects ofthe present disclosure. A person having ordinary skill in the art shouldappreciate that they may readily use the present disclosure as a basisfor designing or modifying other processes and structures for carryingout the same purposes and/or achieving the same advantages of theembodiments introduced herein. A person having ordinary skill in the artshould also realize that such equivalent constructions do not departfrom the spirit and scope of the present disclosure, and that they maymake various changes, substitutions and alterations herein withoutdeparting from the spirit and scope of the present disclosure.

The Abstract at the end of this disclosure is provided to comply with 37C.F.R. § 1.72(b) to allow the reader to quickly ascertain the nature ofthe technical disclosure. It is submitted with the understanding that itwill not be used to interpret or limit the scope or meaning of theclaims.

What is claimed is:
 1. A semiconductor structure comprising: aninterconnect structure comprising a plurality of interconnect featuresdisposed in a dielectric material over a substrate, wherein a firstinterconnect feature of the plurality of interconnect features comprisesa conductive line and a conductive via; and a through-silicon-via (TSV)structure laterally offset from the interconnect structure, the TSVstructure comprising: a first conductive layer extending into thesubstrate; a second conductive layer over the first conductive layer;and a first barrier layer extending between the first conductive layerand the second conductive layer, wherein an interface between theconductive line and the conductive via is substantially level with aninterface between the first conductive layer and the first barrierlayer.
 2. The semiconductor structure of claim 1, wherein the dielectricmaterial comprises a plurality of dielectric layers.
 3. Thesemiconductor structure of claim 2, wherein the first conductive layerof the TSV structure extends through at least one of the plurality ofdielectric layers, and wherein the second conductive layer of the TSVstructure extends from the first conductive layer through each of theplurality of dielectric layers not penetrated by the first conductivelayer.
 4. The semiconductor structure of claim 1, wherein the TSVstructure further comprises a second barrier layer extending along abottom surface and sidewalls of the first conductive layer.
 5. Thesemiconductor structure of claim 4, wherein the TSV structure furthercomprises a liner extending along the bottom surface and the sidewallsof the first conductive layer, the second barrier layer being interposedbetween the first conductive layer and the liner.
 6. The semiconductorstructure of claim 1, wherein a topmost surface of the second conductivelayer is substantially level with a topmost surface of the conductiveline.
 7. The semiconductor structure of claim 1, wherein the secondconductive layer and the conductive line comprise a same conductivematerial.
 8. A semiconductor structure comprising: a substrate; adielectric material over the substrate; a conductive interconnect withinthe dielectric material, the conductive interconnect comprising aconductive line and a conductive via; and a through-silicon-via (TSV)structure laterally spaced apart from the conductive interconnect, theTSV structure extending through the dielectric material and into thesubstrate, the TSV structure comprising: a first conductive layerextending into the substrate; a second conductive layer over the firstconductive layer; and a first barrier layer extending between the firstconductive layer and the second conductive layer, wherein a thickness ofthe conductive line is substantially same as a combined thickness of thefirst barrier layer and the second conductive layer.
 9. Thesemiconductor structure of claim 8, wherein the TSV structure furthercomprises a liner extending along a bottom surface and sidewalls of thefirst conductive layer, and along sidewalls of the second conductivelayer.
 10. The semiconductor structure of claim 8, wherein the firstbarrier layer extends along sidewalls of the second conductive layer.11. The semiconductor structure of claim 8, wherein the TSV structurefurther comprises a second barrier layer extending along a bottom andsidewalls of first conductive layer.
 12. The semiconductor structure ofclaim 8, wherein the conductive line comprises: a second barrier layer;and a third conductive layer over the second barrier layer, wherein thethird conductive layer and the second conductive layer comprise a sameconductive material.
 13. The semiconductor structure of claim 12,wherein the first barrier layer and the second barrier layer comprise asame material.
 14. The semiconductor structure of claim 8, wherein thefirst conductive layer and the second conductive layer have asubstantially same composition.
 15. A semiconductor structurecomprising: a substrate; a first dielectric layer over the substrate; asecond dielectric layer over the first dielectric layer; adual-damascene interconnect extending through the first dielectric layerand the second dielectric layer, the dual-damascene interconnectcomprising: a conductive via within the first dielectric layer; and aconductive line within the second dielectric layer; and athrough-silicon-via (TSV) structure laterally spaced apart from thedual-damascene interconnect, the TSV structure comprising: a firstconductive layer extending through the first dielectric layer and intothe substrate; a second conductive layer within the second dielectriclayer; and a first barrier layer extending between the first conductivelayer and the second conductive layer, wherein a thickness of the seconddielectric layer is substantially same as a combined thickness of thefirst barrier layer and the second conductive layer.
 16. Thesemiconductor structure of claim 15, wherein an interface between thefirst dielectric layer and the second dielectric layer is substantiallylevel with an interface between the first conductive layer and the firstbarrier layer.
 17. The semiconductor structure of claim 15, wherein thedual-damascene interconnect and the second conductive layer comprise asame conductive material.
 18. The semiconductor structure of claim 15,wherein the TSV structure further comprises a second barrier layerextending along and in physical contact with sidewalls of firstconductive layer.
 19. The semiconductor structure of claim 15, wherein atopmost surface of the dual-damascene interconnect is substantiallylevel with a topmost surface of the TSV structure.
 20. The semiconductorstructure of claim 15, wherein a width of the first conductive layer isgreater than a width of the second conductive layer.